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(11) | EP 2 817 373 B1 |
| (12) | EUROPEAN PATENT SPECIFICATION |
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| (54) |
BIODEGRADABLE POLYMER COMPOSITION FOR THE MANUFACTURE OF ARTICLES HAVING A HIGH HEAT DEFLECTION TEMPERATURE BIOLOGISCH ABBAUBARE POLYMERZUSAMMENSETZUNGEN FÜR DIE HERSTELLUNG VON ARTIKELN MIT HOHER FORMBESTÄNDIGKEITSTEMPERATUR COMPOSITION DE POLYMÈRE BIODÉGRADABLE POUR LA FABRICATION D'ARTICLES POSSÉDANT UNE TEMPÉRATURE ÉLEVÉE DE DÉFLECTION À CHAUD |
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| Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention). |
DESCRIPTION
[0001] This invention relates to a biodegradable polymer composition which is particularly suitable for use for the manufacture of articles having a high heat deflection temperature (HDT) by injection moulding and thermoforming.
[0002] This invention also relates to the process of producing the said composition and articles obtained therewith.
[0003] Polylactic acid is a biodegradable thermoplastic polyester originating from a renewal source. Its mechanical properties make it an ideal candidate for the replacement of conventional thermoplastic polymers, especially in the case of applications where high rigidity is required, such as for example in the manufacture of throwaway cutlery, rigid containers or caps for drinks containers.
[0004] Despite the fact that polylactic acid can be used in standard machinery with minimum modifications, some of its properties nevertheless have not hitherto let it be utilised widely and extensively as a replacement for conventional thermoplastic materials.
[0005] In the injection moulding sector, for example, one of the greatest difficulties associated with the use of polylactic acid and its compositions with other biodegradable polymers lies in the high tendency for articles made therewith to deform if subjected to high loads at temperatures above ambient temperature. This is because in the manufactures obtained using normal injection moulding production processes polylactic acid is mainly present as an amorphous polymer, which is therefore only rigid well below its glass transition temperature, of approximately 60°C. Typically this tendency is mitigated by increasing the percentage crystallinity of polylactic acid, for example by subjecting articles to annealing heat treatments. Nevertheless, even though this technique brings about a substantial increase in an article's heat deflection temperature, it also results in its deformation. Consequently special precautions have to be taken during the stages of designing and producing the said articles, which has an adverse effect on their industrial processability.
[0006] In consideration of the above it would therefore be desirable to have a biodegradable composition containing polylactic acid which is capable of being transformed economically and productively into articles having a high heat deflection temperature without compromising their dimensional stability.
[0007] In particular, this invention relates to a biodegradable polymer composition for the production of articles having a high heat deflection temperature comprising:
- i) 50-95 % by weight, preferably 60-90% and even more preferably 68-87% by weight, with respect to the sum of components i and ii, of a polyester of lactic acid;
- ii) 5-50% by weight, preferably 10-40% and even more preferably 13-32% by weight,
with respect to the sum of components i and ii, of at least one aromatic aliphatic
polyester (AAPE) comprising a dicarboxyl component and a diol component comprising
the following structural units:
-[-O-(R11)-O-C(O)-(R13)-C(O)-]-
-1-O-(R12)-O-C(O)-(R14)-C(O)-]-
in which the diol component comprises a -O-(R11)-O- and -O-(R12)-O- units derived from diols, in which R11 and R12 are the same or different and are selected from the group comprising C2-C14 alkylenes, C5-C10 cycloalkylenes, C2-C12 oxyalkylenes, heterocyclic groups and their mixtures, in which the dicarboxylic component comprises -C(O)-(R13)-(O)- units deriving from aliphatic diacids and -C(O)-(R14)-C(O)- units deriving from aromatic diacids, in which R13 is selected from the group comprising C0-C20 alkylenes and their mixtures and the molar percentage of the units derived from the aromatic diacids is more than 50% and less than or equal to 70 mol% of the dicarboxyl component; - iii) 1-25% by weight, more preferably 4-15% by weight, with respect to the total weight of the biodegradable polymer composition, of cellulose fibres;
- iv) 1-10 % by weight, preferably 2-6 % by weight, with respect to the total weight of the biodegradable polymer composition, of a nucleating agent selected from polyesters comprising repeating units of 1,4-butylene succinate, talc and mixtures thereof.
[0008] As far as the lactic acid polyester is concerned, this is advantageously selected from poly-L-lactic acid, poly-D-lactic acid and the stereo complex of poly-D-L-lactic acid or mixtures thereof.
[0009] Polymers or copolymers of polylactic acid containing at least 95% by weight of repeating units derived from L-lactic acid or D-lactic acid or their combinations having a molecular weight Mw of more than 50,000 and a shear viscosity of between 50-500 Pas, preferably between 100-300 Pas (measured according to standard ASTM D3835 at T = 190°C, shear rate = 1000 s-1, D = 1 mm, L/D = 10) are particularly preferred.
[0010] In a particularly preferred embodiment the lactic acid polyester comprises 98% by weight of units deriving from L-lactic acid, 2% of repeated units deriving from D-lactic acid, has a melting point in the range 160-170°C, a glass transition temperature (Tg) in the range 55-65°C and an MFR (measured according to standard ASTM-D1238 at 190°C and 2.16 kg) within the range 10-60 g/10 min, preferably 30-40 g/10 min.
[0011] The process for production of the lactic acid polyester may take place according to any one of the known processes in the state of the art. In particular, this polyester may advantageously be obtained through a polymerisation reaction by opening the ring from the lactide.
[0012] As far as the aliphatic-aromatic polyester AAPE is concerned, the dicarboxyl component comprises units deriving from aliphatic diacids and aromatic diacids of the type described above.
[0013] Of the aliphatic diacids, succinic acid, adipic acid, suberic acid, azelaic acid, sebacic acid, undecandioic acid, dodecandioic acid, brassilic acid, hexadecandioic acid and octadecandioic acid are particularly preferred. Mixtures of these diacids are also particularly useful.
[0014] Diacids having unsaturations within the chain, such as for example itaconic acid and maleic acid, are also included.
[0015] As far as the aromatic diacids are concerned, in the aliphatic-aromatic polyester AAPE these are advantageously selected from dicarboxylic aromatic compounds of the phthalic acid type and their esters and heterocyclic dicarboxylic aromatic compounds and their esters and their mixtures. Preferably the said mixtures comprise up to 30% in moles of dicarboxylic aromatic diacids of the phthalic acid type.
[0016] As far as the heterocyclic dicarboxylic aromatic compounds are concerned, these are advantageously of renewable origin, this term meaning those products obtained from sources which because of their intrinsic characteristics are regenerated in nature or are not exhaustible on the scale of a human lifetime and, by extension, whose use will not prejudice natural resources for future generations. The use of products of renewable origin also helps to reduce CO2 in the atmosphere and reduce the use of non-renewable resources. A typical example of a renewable source is that of plant crops.
[0017] As far as dicarboxylic aromatic diacids of the phthalic acid type are concerned, terephthalic acid is particularly preferred, while with regard to the heterocyclic dicarboxylic aromatic compounds 2,5-furandicarboxylic acid is particularly preferred.
[0018] The content of units deriving from aromatic diacids in the aliphatic-aromatic polyester AAPE is 40-70%, preferably higher than 50 % and more preferably between 55-60% in moles with respect to the total diacids content in moles.
[0019] As regards the diol component of the aliphatic-aromatic polyester AAPE, this derives from diols preferably selected from 1,2-ethandiol, 1,2-propandiol, 1,3-propandiol, 1,4-butandiol, 1,5-pentandiol, 1,6-hexandiol, 1,7-heptandiol, 1,8-octandiol, 1,9-nonandiol, 1,10-decandiol, 1,11-undecandiol, 1,12-dodecandiol, 1,13-tridecandiol, 1,4-cyclohexanedimethanol, propylene glycol, neo-pentyl glycol, 2-methyl-1,3-propandiol, dianhydrosorbitol, dianhydromannitol, dianhydroinitol, cyclohexandiol, cyclohexanmethandiol and their mixtures. Among the diols, 1,2-ethandiol, 1,3 propandiol, 1,4-butandiol and their mixtures are particularly preferred.
[0020] The aliphatic-aromatic polyester AAPE may contain at least one hydroxy acid in a quantity of between 0-49%, preferably between 0-30% in moles with respect to the moles of aliphatic dicarboxylic acid, in addition to the base monomers. Examples of convenient hydroxy acids are glycolic acid, hydroxybutyric acid, hydroxycaproic acid, hydroxyvaleric acid, 7-hydroxyheptanoic acid, 8-hydroxycaproic acid, 9-hydroxynonanoic acid, lactic acid or lactides. The hydroxy acids may be inserted into the chain as such or may be first caused to react with diacids or diols.
[0021] Long molecules with two functional groups, including those with a functional group which is not in a terminal position, may also be added in quantities not exceeding 10%. Examples are dimer acids, ricinoleic acid and acids incorporating epoxy functional groups and also polyoxyethylenes having a molecular weight of between 200 and 10,000.
[0022] Amines, amino acids and amino alcohols may also be present in percentages up to 30% in moles in relation to all the other components.
[0023] In the process for preparation of the aliphatic-aromatic polyester AAPE one or more molecules having multiple functional groups may advantageously be added in quantities between 0.1 and 3% in moles with respect to the quantity of dicarboxylic acids (and any hydroxy acids) in order to obtain branched products. Examples of these molecules are glycerol, pentaerythritol, trimethylol propane, citric acid, dipentaerythritol, monoanhydrosorbitol, monohydromannitol, acid triglycerides, polyglycerols, etc.
[0024] In a particularly preferred embodiment the aliphatic-aromatic polyester AAPE is biodegradable in the meaning of standard EN 13432.
[0025] The molecular weight Mn of the aliphatic-aromatic polyester AAPE is preferably greater than 30,000. As far as the polydispersity index of the molecular weights Mw / Mn is concerned, this on the other hand is preferably between 1.5 and 10.
[0026] The molecular weights Mn and Mw may be measured by Gel Permeation Chromatography (GPC). The determination may be performed with the chromatography system held at 40°C, using a set of three columns in series (particle diameter 5 µ and respective porosities of 500 A, 1000 A and 10,000 A), a refractive index detector, chloroform as eluent (flow 1 ml/min) and using polystyrene as the reference standard.
[0027] The Melt Flow Rate (MFR) of the aliphatic-aromatic polyester AAPE is preferably between 500 and 1 g/10 min, more preferably between 100 and 5 g/10 min, even more preferably between 50 and 6 g/10 min (measurement made at 190°C/2.16 kg according to standard ASTM D1238-89 "Standard Test Method for Melt Flow Rates of Thermoplastics by Extrusion Plastometer").
[0028] Preferably the aliphatic-aromatic polyester AAPE has an inherent viscosity (measured using an Ubbelohde viscosimeter for solutions of concentration 0.2 g/dl in CHCl3 at 25°C) of more than 0.4, preferably between 0.4 and 2, more preferably between 0.7 and 1.5 dl/g.
[0029] The aliphatic-aromatic polyester AAPE may be a block copolymer or a random copolymer, the latter being preferred.
[0030] The process for production of the aliphatic-aromatic polyester AAPE may take place according to any of the known processes in the state of the art. In particular this polyester may advantageously be obtained by means of a polycondensation reaction. Advantageously the process of polymerising the polyester may be performed in the presence of a suitable catalyst. Among such suitable catalysts mention may be made by way of example of organometallic compounds of tin, for example stannoic acid derivatives, titanium compounds, for example orthobutyltitanate, aluminium compounds, for example Al-triisopropyl, and compounds of antimony and zinc.
[0031] The aliphatic-aromatic polyester AAPE may also be obtained by a process of reactive extrusion from a precursor polyester (PP) comprising units deriving from at least one diacid and at least one substantially linear diol with a MFI of 5-30 dl/g at 190°C and 2.16 kg, having a mean weighted molecular weight Mw measured by GPC of between 60,000-120,000 and an content of active sites such as unsaturations in an amount of 0.1-1% in moles and/or terminal acid groups in a quantity of 10-200 meq of KOH, the said reactive extrusion process being performed through the addition of a compound selected from peroxides, epoxides or carbodiimides, such as those mentioned above.
[0032] If the said reactive extrusion process is carried out using peroxides, these are used in quantities of 0.001-0.2% and preferably 0.01-0.1% by weight with respect to the sum of the polymers fed to the reactive extrusion process.
[0033] As far as the addition of epoxides is concerned, these are preferably used in a quantity of 0.1-2%, more preferably 0.2-1% by weight with respect to the sum of the polymers fed to the reactive extrusion process.
[0034] If carbodiimides are used, these are preferably used in a quantity of 0.05-2%, more preferably 0.1-1% by weight with respect to the sum of the polymers fed to the reactive extrusion process.
[0036] Preferably the said precursor polyester PP has an MFI of 5-30 and more preferably 7-20 g/10 min at 190°C and 2.16 kg, a shear viscosity of 400-900 Pas and a weighted mean molecular weight Mw of preferably between 100,000-130,000.
[0037] Preferably the said precursor polyester PP has an unsaturations content of 0.1-0.8% and more preferably 0.2-0.7% in moles.
[0038] The unsaturations may be generated in situ during the polymerisation stage or processing of the precursor polyester PP or through the insertion of suitable unsaturated monomers or unsaturated chain endings.
[0040] Among unsaturated chain terminations those preferred are those having the following structure:
T-(CH2)n-CH=CH2
in which "T" is a group capable of reacting with carboxyl and/or hydroxyl groups, for example a hydroxyl, carboxyl, amine, amide or stereo group, and "n" is a whole number between 0 and 13.
[0043] The whole number "n" preferably lies between 1 and 13, more preferably between 3 and 13 and even more preferably 8 or 9.
[0044] Particularly preferred unsaturated chain terminators include omega-undecenoic acid, omega-undecenyl alcohol and their mixtures.
[0045] The presence of unsaturations and/or adducts deriving from the reaction of these following reactive extrusion may be determined by different methods which are well known to those skilled in the art, such as NMR spectroscopy or methanolysis reactions of the polymer chain coupled with chromatographic methods combined with mass spectrometry.
[0046] Those skilled in the art will easily be able to identify the structures relating to unsaturations as such or adducts deriving from their reaction following reactive extrusion.
[0047] As far as measurement of the unsaturations content by NMR is concerned, this may be performed by 300 MHz H1 NMR using a pulse-acquisition sequence characterised by a pulse phase of 30°, a spectral amplitude = 4 kHz, a delay of 5 seconds and performing 6000 scans.
[0048] Preferably the aliphatic-aromatic polyester AAPE can be obtained by a reactive extrusion process from a precursor polyester PP having a terminal acid groups content of 35-150 meq of KOH/kg of polyester.
[0049] The terminal acid groups content may be measured as follows: 1.5-3 g of the polyester are placed in a 100 ml flask together with 60 ml of chloroform. After the polyester has completely dissolved 25 ml of 2-propanol are added, and immediately before analysis 1 ml of deionised water. The solution so obtained is titrated against a previously standardised solution of KOH in ethanol. An appropriate indicator, such as for example a glass electrode for acid-base titrations in non-aqueous solvents, is used to determine the end point of the titration. The terminal acid groups content is calculated on the basis of the consumption of KOH solution in ethanol using the following equation:
in which: Veq = ml of KOH solution in ethanol at the end point of the titration of the sample;
Vb = ml of KOH solution in ethanol required to achieve a pH = 9.5 in the blank titration;
T = concentration of the KOH solution in ethanol expressed in moles/litre;
P = weight of the sample in grams.
[0050] The process of producing the precursor polyester PP may take place according to any of the processes known in the state of the art described above.
[0051] The biodegradable polymer composition according to the present invention comprises 1-25% by weight of cellulose fibre, more preferably 4-15% by weight. It has in fact been found that such a cellulose fibre content has the effect of improving the properties of the polymer composition enabling it to be used to manufacture articles having a high heat deflection temperature and particularly high dimensional stability.
[0052] By "dimensional stability" is meant the ability of an object to maintain its original shape over time or following annealing treatments such as for example those described below.
[0053] It has also unexpectedly been found that the use of cellulose fibre having a length/diameter ratio (i.e. L/D) < 40, preferably L/D < 30 and even more preferably L/D < 20 is particularly advantageous for the properties of the biodegradable polymer composition according to the present invention because, in addition to contributing to the abovementioned properties of dimensional stability and high heat deflection temperature, it does not give rise to excessive increases in the elastic modulus or significant reductions in the deformation of the biodegradable polymer composition on failure, nor an appreciable reduction in its flow properties in the molten state.
[0054] Concerning the nucleating agents of the biodegradable polymeric composition, they are selected from polyesters comprising repeating units of 1,4-butylene succinate, talc and mixtures thereof.
[0055] With regard to the polyesters comprising repeating units of 1,4-butylene succinate, poly(1,4-butylene succinate) and poly(1,4-butylene succinate-co-1,4-butylene alkylate) copolymers are preferred, poly(1,4-butylene succinate) being more preferred. As far as poly(1,4-butylene succinate-co-1,4-butylene alkylate) copolymers are concerned, they advantageously shows a crystallization temperature higher than 80°C, more preferably higher than 90°C still more preferably higher than 100°. The 1,4-butylene-alkylate repeating units advantageously comprise C2-C20 aliphatic diacids residues and, among C2-C20 aliphatic diacids, adipic acid, sebacic acid and azelaic acid and mixtures thereof are preferred. Preferably, the polyesters comprising repeating units of 1,4-butylene succinate have a MFR (determined according to ASTM 1238 -10 at 190 °C and 2,16 kg) higher than 20 g/10 minutes, preferably higher than 30 g/10 minutes.
[0056] In a preferred embodiment of the present invention, the nucleating agents of the biodegradable polymeric composition comprises a mixture of polyesters comprising repeating units of 1,4-butylene succinate and talc, wherein said mixture comprises 10-95 wt % and more preferably 30-85 wt % of said polyesters. In a particularly preferred embodiment the polyester of said mixture is poly(1,-4 butylene succinate).
[0057] The polymer composition according to this invention may also contain one or more other additives, for example fillers, anti-caking agents, cross-linking agents, compatibilizing agents, plasticisers, pigments and dyes.
[0058] As far as fillers are concerned, these may be inorganic and/or organic. Examples of particularly preferred inorganic fillers are: sepiolite, montmorillonite, calcium carbonate, silica, mica, kaolin, titanium dioxide and wollastonite.
[0059] The process of producing the polymer composition according to this invention may take place according to any of the processes known in the state of the art. Advantageously the polymer composition according to this invention is produced by means of extrusion processes in which the components are mixed in the fused state. When extruding the composition the components may be fed altogether or one or more of these may be fed separately along the extruder. In a particularly preferred embodiment of the process for producing the biodegradable polymer composition according to the invention the components i) -iv) are fed altogether to the extruder and, in such a case, the use of cellulose fibers with L/D < 40 is particularly preferred in order to obtain an homogeneous distribution of the fibers.
[0060] Without willing to be bound to any specific theory, it is believed that the presence of cellulose fibers improve the processability and the quality of the moulded manufact without leading to the formation of visible weld lines (weld lines are also known as "knit lines").
[0061] The biodegradable polymer composition according to this invention is particularly suitable for use in injection moulding and thermoforming, and in spinning.
[0062] Its properties may in fact allow it to be used to manufacture injection moulded or thermoformed articles having a high heat deflection temperature (HDT) and high dimensional stability.
[0063] With the expression "high heat deflection temperature (HDT), in the present invention it is meant a HDT higher than 100 °C when measured according to standard ASTM-D648 using a load of 0.455 MPa or higher than 63 °C when measured according to standard ASTM-D648 using a load of 1,82 MPa. This allows the use of the injection moulded or thermoformed articles without occurrence of deformations if subjected to high loads at high temperatures and is particularly advantageous for the production of throwaway cutlery, cups, rigid containers, caps for the dispensing of drinks, preferably hot drinks, lids and covers, and packaging for food which can be reheated in conventional ovens and microwaves.
[0064] The biodegradable polymer composition according to the invention is therefore particularly suitable for the manufacture of throwaway cutlery, cups, rigid containers, caps for the dispensing of drinks, preferably hot drinks, lids and covers, and packaging for food.
[0065] As far as injection moulding is concerned, the biodegradable polymer composition according to the present invention has the further advantage that it can be fed to conventional machinery without requiring substantial changes to normal operating conditions in comparison with other conventional polymers such as for example polyethylene, polypropylene, polystyrene and ABS. Preferably, in the case of objects having a maximum thickness of the order of 1 millimetre, these may be moulded using a fusion temperature of 210°C, an oleodynamic pressure of 80 bar, a cooling time of 4 sec and a cycle time of 12 sec.
[0066] In a particularly preferred embodiment, injection moulded articles comprising the composition according to this invention are subjected to hot annealing treatments at temperatures between 70 and 150°C. This invention also relates to articles obtained by means of the said annealing treatments (known as annealed products).
[0067] These annealing treatments may advantageously be performed in an unconfined environment at constant temperature, for example within a stove. In this case the annealing treatments are preferably carried out at temperatures between 80-150°C and with residence times of 30 sec-60 min, preferably 40 sec-30 min and even more preferably 40 sec-5 min, with this being particularly advantageous from the production point of view. The specific conditions which have to be used will vary depending on the dimensions of the object which has to be subjected to annealing treatment and the degree of heat resistance required by the application. In general in the case of thick objects it is preferable to use higher temperatures and/or longer residence times.
[0068] The said annealing treatments may also be performed in a confined environment, for example within preheated moulds at constant temperature, preferably between 80-100°C, for 1-5 minutes. The specific conditions which have to be used will vary depending upon the size of the object being subjected to annealing treatment. In general, in the case of thick objects it is preferable to use longer residence times.
[0069] Figure 1 and Figure 2 respectively show the front and side view of a fork manufactured with the biodegradable composition according to the invention wherein "L" represents the length, "W" the width and "H" the heigth of the fork.
[0070] The invention will now be illustrated by a number of embodiments which are to be regarded by way of example and not restrictive of the scope of the protection of this patent application.
EXAMPLES
[0071] In the examples described below:
- Shear viscosity was measured using a Goettfert Rheotester 2000 model rheometer according to standard ASTM-D3835 at a temperature of 190°C using a capillary with D = 1 mm and L/D = 10 flat entry.
- Heat deflection temperature (HDT) was measured according to standard ASTM-D648 using two different loads, 0.455 MPa and 1.82 MPa, on moulded test specimens of the "bar" type (length 127 mm, width 12.7 mm, thickness 3.2 mm) using Ceast 6510 Test-A-Matic model equipment. HDT values were determined in triplicate for each composition. The value stated corresponds to the arithmetic mean of the measured values.
- Dimensional stability for "bar" type specimens: it was measured on moulded test specimens
of the "bar" type (length 127 mm, width 12.7 mm, thickness 3.2 mm) using a Mitutoyo
Digimatic CD-20D model micrometer with an accuracy of ± 0.01 mm. Dimensional stability
values were determined in triplicate for each composition. The value stated corresponds
to the arithmetic mean of the measured values.
The method for measuring dimensional stability comprises calculating the percentage dimensional change (PDC) experienced by the object following annealing treatment.
The percentage dimensional change (PDC) is determined using the following formula:
where:Df is the dimension of the test specimen after treatment, and
Do is its initial dimension.
A positive value for PDC indicates expansion of the test specimen, while a negative value indicates contraction.
The lengths and widths of the test specimens have been taken into consideration in this invention. Test specimens having a PDC < 1% for both dimensions measured are regarded as being dimensionally stable. - Dimensional stability for "fork" type specimens: it was measured on moulded test specimens
of the "fork" type as shown in Fig 1 and 2 (length "L" 168,62 mm, width "W" 22,57
mm, height "H" 14,36 mm) using a digital caliper mod. MIB (Germany) with a resolution
of 0.01mm and measuring range 0÷150mm
The method for measuring dimensional stability for the "fork" type specimens comprises calculating the Average Percentage Height Reduction (APHR) experienced by the object following an annealing treatment.
The Average Percentage Height Reduction (APHR) is determined using the following formula:
where:- n is the total tine number of a fork.
- (PHR)i is the percentage height reduction of the tip of the ith tine of a fork and is calculated by the following formula:
where:- H0 is the height of the tine tip before annealing, measured with respect to a reference plane
- Hf is the height of the same tine tip after annealing, measured with respect to said reference plane.
- Mechanical properties were measured according to standard ASTM D790-03 - Method B - V0 = 13 mm/min on standard test specimens of the "bar" type using an Instron 4301 model dynamometer. The following were determined: Elastic Modulus (in MPa), deformation on failure (as %) and ultimate tensile strength (in MPa).
EXAMPLE 1
[0072]
Table 1 - Compositions in Example 1
| Example | PLA | AAPE | Anti-caking agent | Nucleating agent | Cellulose fibre | Inorganic filler | Hydrolysis stabiliser |
| 1 | 70.40 | 10.40 | 0.6 | 3 | 15 | 0.6 | 0.04 |
[0073] Where not explicitly indicated the figures are expressed in parts.
- PLA =
- polylactic acid containing 98% of L-Lactic and 2% of D-Lactic, melting point Tm = 165°C, weighted mean molecular weight Mw = 166000, intrinsic viscosity = 0.97 dl/g and shear viscosity = 120 Pas measured according to standard ASTM-D3835 at T = 190°C, shear rate = 1000 s-1, and capillary D = 1 mm with L/D = 10.
- AAPE =
- poly(butylenesebacate-co-butyleneterephlate) (PBST) having 56% in moles of terephthalic acid with respect to the sum of the aliphatic diacids and aromatic diacids, and having MFI = 14 g/10 min (at 190°C and 2.16 kg), and shear viscosity η = 570 Pas measured according to standard ASTM-D3835 at T = 180°C, shear rate = 104 s-1, and capillary D =1 mm with L/D = 30.
Anti-caking agent = oleamide of plant origin
Nucleating agent = micronised talc (particle size = 2-10 microns)
Cellulose fibre = 100% pure cellulose fibre having L/D = 18
Inorganic filler = Titanium dioxide
Hydrolysis stabiliser = styrene-glycidyl ether-methylmethacrylate copolymer having Mw = 7300, Mn = 2750, Tg = 54°C, equivalent weight of epoxide = 285 g/mol, number of epoxides per molecule = 10.
[0074] The composition in Table 1 was fed to a model APV2030 co-rotating twin-screw extruder under the following conditions:
D = 30 mm;
L/D = 40;
RPM = 170;
thermal profile = 30°C-90°C-140°C-150°C-9x200°C-3x150°C.
[0075] The extrudate was cooled in a water bath and granulated. The granules obtained were dried for 3 hours in a Moretto DH100 model plastics dryer with air circulating at T = 60°C. After drying the granules had a shear viscosity of 180 Pas measured according to standard ASTM-D3835 at T = 190°C, shear rate = 1000s-1, and capillary D =1 mm with L/D = 10. The granules were then injection moulded in a Sandretto S7/60 model press in a mould to produce standard "bar" type test specimens (length 127 mm, width 12.7 mm, thickness 3.2 mm) and "fork" type specimens (length "L" 168,62 mm, width "W" 22,57 mm, height "H" 14,36 mm) suitable for HDT tests according to standard ASTM-D648 and also suitable for mechanical bend tests according to standard ASTM-D790, using the following injection moulding operating conditions:
injection T = 200°C;
Injection pressure = 1250 bar;
Injection time = 0.7 sec;
Injection flowrate = 25 cm3/sec;
Holding pressure = 200 bar;
Holding time = 11 sec;
Cooling time = 25 sec;
Mould temperature = 20°C;
Screw rotation = 80 rpm.
[0076] The test specimens were examined to determine their thermal, mechanical properties and their dimensions. The results of the characterisations are shown in Table 5-6.
EXAMPLE 2
[0077] The moulded test specimens were then subjected to annealing treatment in an unconfined environment in a Venti-Line VL115 model stove with circulating air using the following operating conditions: Temperature = 90°C, time = 60 minutes.
[0078] After cooling and reconditioning at T = 23°C and 55% RH for 1 day the annealed test specimens were then examined to determine dimensional stability, mechanical properties and heat deflection temperature HDT.
EXAMPLES 3-5
[0080] The moulded test specimens according to Example 1 were subjected to three different annealing treatments using the operating conditions shown in Table 3:
Table 3 - Annealing conditions
| Example 3 | Example 4 | Example 5 | |
| T(°C) | 90 | 150 | 150 |
| time (minutes) | 5 | 15 | 2.5 |
[0081] After cooling and reconditioning at T = 23°C and 55% RH for 1 day the annealed test specimens were examined to determine their dimensional stability (PDC) and heat deflection temperature (HDT) (Tables 6-7).
EXAMPLES 6-11
[0082] The compositions in Table 4 have been extruded and moulded according to Example 1 to obtain "fork"type samples.
Table 4 - Compositions in Examples 6-11
| Example | PLA | AAPE | Anti-caking agent | Nucleating agent | Cellulose fibre | Inorganic filler | Hydrolysis stabiliser | |
| talc | PBS | |||||||
| 6 (comparison) | 83,13 | 11,87 | 0.6 | 0,6 | 2,4 | 0 | 0.6 | 0.04 |
| 7 (comparison) | 72,625 | 15 | 0.6 | 0 | 0 | 10,375 | 0.6 | 0.04 |
| 8 | 70 | 15 | 0.6 | 3 | 0 | 10 | 0.6 | 0.04 |
| 9 | 70 | 15 | 0.6 | 0 | 3 | 10 | 0.6 | 0.04 |
| 10 | 70 | 15 | 0.6 | 0,6 | 2,4 | 10 | 0.6 | 0.04 |
| 11 | 69 | 9,80 | 0.6 | 0 | 5 | 15 | 0.6 | 0.04 |
[0083] Where not explicitly indicated the figures are expressed in parts.
- PLA =
- polylactic acid containing 98% of L-Lactic and 2% of D-Lactic, melting point Tm = 165°C, weighted mean molecular weight Mw = 166000, intrinsic viscosity = 0.97 dl/g and shear viscosity = 120 Pas measured according to standard ASTM-D3835 at T = 190°C, shear rate = 1000 s-1, and capillary D = 1 mm with L/D = 10.
- AAPE =
- poly(butylenesebacate-co-butyleneterephlate) (PBST) having 56% in moles of terephthalic acid with respect to the sum of the aliphatic diacids and aromatic diacids, and having MFI = 14 g/10 min (at 190°C and 2.16 kg), and shear viscosity η = 570 Pas measured according to standard ASTM-D3835 at T = 180°C, shear rate = 104 s-1, and capillary D =1 mm with L/D = 30.
Anti-caking agent = oleamide of plant origin
Nucleating agent : talc = micronised talc (particle size 2-10 microns) PBS = poly(1,4-butylene succinate) MFR 46 g/10' (measured according to ASTM 1238 -10 at 190 °C/2,16 kg)
Cellulose fibre = 100% pure cellulose fibre having L/D = 18
Inorganic filler = Titanium dioxide
Hydrolysis stabiliser = styrene-glycidyl ether-methylmethacrylate copolymer having Mw = 7300, Mn = 2750, Tg = 54°C, equivalent weight of epoxide = 285 g/mol, number of epoxides per molecule = 10.
[0084] The forks according to Examples 2 and 6-11 thus obtained were annealed at 95°C for 4 minutes in a tunnel oven mod. AIR JET-1STD5M manufactured by Sermac (Italy) with length =2.5m. The forks were placed onto a belt moving along into the oven at a constant speed. The belt was made by a PTFE/Glass-Fiber perforated tissue to ensure uniform temperature everywhere around the fork.
[0085] The oven was uniformly heated by a circulating stream of hot air and the effective temperature inside the oven was monitored by four thermal sensors type "K" mod. Lutron TM-947SD placed along the oven near the moving belt.
[0086] After cooling and reconditioning at T = 23°C and 55% RH for 1 day the annealed test specimens were examined to determine their Average Percentage Height Reduction (APHR) (Table 8).
Table 5 - Mechanical characterisation according to ASTM-D790
| Elastic modulus (MPa) | Deformation on failure (%) | Ultimate tensile strength (MPa) | |
| Example 1 | 3680 | 3.3 | 73 |
| Example 2 | 3974 | 2.5 | 70 |
Table 6 - HDT according to ASTM-D648
| HDT (°C) | ||
| load = 0.455 MPa | load = 1.82 MPa | |
| Example 1 | 51 | 48 |
| Example 2 | 113 | 68 |
| Example 3 | 110 | 64 |
| Example 4 | 129 | 71 |
| Example 5 | 118 | 67 |
| Example 6 (comparison) | 97 | 62 |
| Example 7 (comparison) | 117 | 64 |
| Example 8 | 111 | 67 |
| Example 9 | 108 | 66 |
| Example 10 | 110 | 65 |
| Example 11 | 109 | 68 |
Table 7 - Dimensional stability PDC for "bar" type specimens
| PDC (%) | ||
| width | Length | |
| Example 2 | -0.42 | -0.49 |
| Example 3 | -0.18 | -0.49 |
| Example 4 | -0.47 | -0.67 |
| Example 5 | -0.47 | -0.59 |
| Example 11 | -0,15 | .0,52 |
Table 8 - Dimensional stability APHR for "fork" type specimens
| APHR (%) | |
| Example 2 | 12 |
| Example 6 (comparison) | 65 |
| Example 7 (comparison) | 55 |
| Example 8 | 32 |
| Example 9 | 20 |
| Example 10 | 18 |
| Example 11 | 15 |
1. Biodegradable polymeric composition for preparing articles having high heat deflection
temperature comprising:
i) 50-95% by weight, based on the sum of components i. and ii., of a polyester of lactic acid;
ii) 5-50 % by weight, based on the sum of components i. and ii., of at least one aliphatic-aromatic
polyester (AAPE) comprising a dicarboxylic component and a dihydroxylic component
which comprise the following structural units:
-[-O-(R11)-O-C(O)-(R13)-C(O)-]-
-[-O-(R12)-O-C(O)-(R14)-C(O)-]-
wherein the dihydroxylic component comprises units -O-(R11)-O- and - O-(R12)-O- deriving
from diols, wherein R11 e R12 are the same or different and are selected from the
group consisting of C2-C14 alkylenes, C5-C10 cycloalkylenes, C2-C12 oxyalkylenes,
heterocyclic groups and mixtures thereof, wherein the dicarboxylic component comprises
units-C(O)-(R13)-C(O)-deriving from aliphatic diacids and units -C(O)-(R14)-C(O)-
deriving from aromatic diacids, wherein R13 is selected from the group consisting
of C0-C20 alkylenes and their mixtures and the molar percentage of the units deriving
from aromatic diacids is higher of 50 % and lower than 70% of the dicarboxylic component.
iii) 1-25% by weight, with respect to the total weight of the biodegradable polymer composition, of cellulose fibres;
iv) 1-10 % by weight, with respect to the total weight of the biodegradable polymer composition, of a nucleating agent selected from polyesters comprising repeating units of 1,4-butylene succinate, talc and mixtures thereof.
2. Biodegradable composition according to Claim 1, wherein the polyester of lactic acid
is selected from the group consisting of poly-L-lactic acid, poly-D-lactic acid and
stereocomplex of the poly-L-lactic acid, poly-D-lactic acid or mixtures thereof.
3. Biodegradable composition according to Claim 1, wherein the aliphatic diacid of the
AAPE are succinic acid, adipic acid, suberic acid, azelaic acid, sebacic acid, undecandioic
acid, dodecandioic acid, brassylic acid, hexadecandioic acid and octadecandioic acid
and mixtures thereof.
4. Biodegradable composition according to Claim 1, wherein the aromatic diacid are selected
from dicarboxylic aromatic compounds of the phthalic acid type and their esters and
heterocyclic aromatic compounds and their esters and mixtures thereof.
5. Biodegradable composition according to Claim 4, wherein the heterocyclic aromatic
compound is 2,5 -furanedicarboxylic acid.
6. Biodegradable composition according to Claim 4, wherein the dicarboxylic aromatic
compound of the phthalic acid type is terephthalic acid.
7. Biodegradable composition according to any of claims 1-6, wherein the AAPE is biodegradable
according to the EN 13432 norm.
8. Biodegradable composition according to any of claims 1-7, wherein the nucleating agent
comprises a mixture of polyesters comprising repeating units of 1,4-butylene succinate
and talc, said mixture comprising 10-95 % by weight of said polyesters.
9. Biodegradable composition according to claim 8, wherein the fibers show a length/diameter
ratio < 40.
10. Biodegradable composition according to anyl of claims 1-9, wherein the polyester comprising
repeating units of 1,4-butylene succinate is poly(1,4-butylene succinate).
11. Injection molded articles comprising the biodegradable composition according to any
of claims 1-10.
12. Thermoformed articles comprising the biodegradable composition according to any of
claims 1-10.
13. Annealing process of the injection molded articles according to claim 11, said process
being performed at a temperature comprised between 70 and 150 °C.
14. Process according to claim 13, performed in a non confined environment at a constant
temperature.
15. Process according to Claim 14, performed at a temperature comprised between 80 and
150 °C and with residence time comprised between 30 seconds and 60 minutes.
16. Process according to Claim 13, performed in a confined environment.
17. Process according to Claim 16, performed in constant temperature pre-heated molds.
18. Process according to Claim 17, performer at a temperature comprised between 80 and
100 °C and with residence time comprised between 1 and 5 minutes.
19. Annealed products obtainable by the annealing process according to any of claims 13-18.
1. Bioabbaubare Polymerzusammensetzung zur Herstellung von Erzeugnissen mit hoher Hitzedeflektionstemperatur,
umfassend:
i) 50 bis 95 Gew.%, auf Basis der Summe der Komponenten i und ii, eines Polyesters aus Milchsäure;
ii) 5 bis 50 Gew.%, auf Basis der Summe der Komponenten i und ii, mindestens eines
aliphatisch-aromatischen Polyesters (AAPE), der eine Dicarbonsäurekomponente und eine
Dihydroxysäurekomponente umfasst, die die folgenden Struktureinheiten umfassen:
-[-O-(R11)-O-C(O)-(R13)-C(O)-]-
-[-O-(R12)-O-C(O)-(R14)-C(O)-]-
worin die Dihydroxykomponente Einheiten -O-(R11)-O- und -O-(R12)-O- umfasst, die von
Diolen abgeleitet sind, worin R11 und R12 gleich oder unterschiedlich sind und aus
der Gruppe bestehend aus C2-C 14-Alkylen, C5-C10-Cycloalkylen, C2-C12-Oxyalkylen,
heterocyclischen Gruppen und Mischungen daraus ausgewählt sind, worin die Dicarbonsäurekomponente
Einheiten -C(O)-(R13)-C(O)-, abgeleitet von aliphatischen Disäuren und Einheiten -C(O)-(R14)-C(O)-
abgeleitet von aromatischen Disäuren umfasst, worin R13 aus der Gruppe, bestehend
aus CO-C20-Alkylen und Mischungen daraus ausgewählt ist, und der Molprozentwert von
Einheiten, die von aromatischen Disäuren abgeleitet sind, höher als 50 % und niedriger
als 70 % der Dicarbonsäurekomponente beträgt;
iii) 1 bis 25 Gew.% in Bezug auf das Gesamtgewicht der bioabbaubaren Polymerzusammensetzung an Cellulosefasern;
iv) 1 bis 10 Gew.% in Bezug auf das Gesamtgewicht der bioabbaubaren Polymerzusammensetzung eines Nukleiermittels ausgewählt aus Polyestern, die Wiederholungseinheiten aus 1,4-Butylensuccinat umfassen, Talk und Mischungen daraus.
2. Bioabbaubare Zusammensetzung gemäß Anspruch 1, worin der Polyester aus Milchsäure
aus der Gruppe, bestehend aus Poly-L-Milchsäure, Poly-D-Milchsäure und einem Stereokomplex
der Poly-L-Milchsäure, Poly-D-Milchsäure oder Mischungen daraus ausgewählt ist.
3. Bioabbaubare Zusammensetzung gemäß Anspruch 1, worin die aliphatische Disäure des
AAPE Bernsteinsäure, Adipinsäure, Suberinsäure, Azelainsäure, Sebacinsäure, Undecandisäure,
Dodecandisäure, Bassylsäure, Hexadecandisäure und Octadecandisäure und Mischungen
daraus sind.
4. Bioabbaubare Zusammensetzung gemäß Anspruch 1, worin die aromatische Disäure aus aromatischen
Dicarboxylverbindungen vom Phthalsäuretyp und deren Estern und heterocyclischen aromatischen
Verbindungen und deren Estern und Mischungen daraus ausgewählt sind.
5. Bioabbaubare Zusammensetzung gemäß Anspruch 4, worin die heterocyclische aromatische
Verbindung 2,5-Furandicarbonsäure ist.
6. Bioabbaubare Zusammensetzung gemäß Anspruch 4, worin die aromatische Dicarboxylverbindung
vom Phthalsäuretyp Terephthalsäure ist.
7. Bioabbaubare Zusammensetzung gemäß irgendeinem der Ansprüche 1 bis 6, worin der AAPE
gemäß der Norm EN 13432 bioabbaubar ist.
8. Bioabbaubare Zusammensetzung gemäß irgendeinem der Ansprüche 1 bis 7, worin das Nukleiermittel
eine Mischung aus Polyestern, die Wiederholungseinheiten aus 1,4-Butylensuccinat umfassen,
und Talk ist, wobei die Mischung 10 bis 95 Gew.% der Polyester umfasst.
9. Bioabbaubare Zusammensetzung gemäß Anspruch 8, worin die Fasern ein Verhältnis von
Länge/Durchmesser < 40 zeigt.
10. Bioabbaubare Zusammensetzung gemäß irgendeinem der Ansprüche 1 bis 9, worin der Polyester,
der Wiederholungseinheiten aus 1,4-Butylensuccinat umfasst, Poly(1,4-butylensuccinat)
ist.
11. Spritzguss-geformte Erzeugnisse, die die bioabbaubare Zusammensetzung gemäß irgendeinem
der Ansprüche 1 bis 10 umfassen.
12. Thermogeformte Erzeugnisse, die die bioabbaubare Zusammensetzung gemäß irgendeinem
der Ansprüche 1 bis 10 umfassen.
13. Temperverfahren für Spritzguss-geformte Erzeugnisse gemäß Anspruch 11, worin das Verfahren
bei einer Temperatur zwischen 70 und 150°C durchgeführt wird.
14. Verfahren gemäß Anspruch 13, das in einer nicht-abgeschlossenen Umgebung bei konstanter
Temperatur durchgeführt wird.
15. Verfahren gemäß Anspruch 14, das bei einer Temperatur zwischen 80 und 150°C mit einer
Verweilzeit zwischen 30 Sekunden und 60 Minuten durchgeführt wird.
16. Verfahren gemäß Anspruch 13, das in einer abgeschlossenen Umgebung durchgeführt wird.
17. Verfahren gemäß Anspruch 16, das in vorerwärmten Formungswerkzeugen bei konstanter
Temperatur durchgeführt wird.
18. Verfahren gemäß Anspruch 17, das bei einer Temperatur zwischen 80 und 100°C mit einer
Verweilzeit zwischen 1 und 5 Minuten durchgeführt wird.
19. Getemperte Erzeugnisse, die durch das Temperverfahren gemäß irgendeinem der Ansprüche
13 bis 18 erhältlich sind.
1. Composition polymère biodégradable pour préparer des articles ayant une température
de déformation à la chaleur élevée, comprenant :
i) 50 à 95 % en poids, par rapport à la somme des composants i) et ii), d'un polyester d'acide lactique ;
ii) 5 à 50 % en poids, par rapport à la somme des composants i) et ii), d'au moins
un polyester aliphatique-aromatique (AAPE) comprenant un composant dicarboxylique
et un composant dihydroxylique comprenant les motifs structurels suivants :
-[-O-(R11)-O-C(O)-(R13)-C(O)-]-
-[-O-(R12)-O-C(O)-(R14)-C(O)-]-
où le composant dihydroxylique comprend des motifs -O-(R11)-O- et -O-(R12)-O-dérivant
de diols, où R11 et R12 sont identiques ou différents et sont choisis dans le groupe
constitué par les alkylènes en C2 à C14, les cycloalkylènes en C5 à C10, les oxyalkylènes en C2 à C12, les groupes hétérocycliques et leurs mélanges, où le composant dicarboxylique comprend
des motifs -C(O)-(R13)-C(O)- dérivant de diacides aliphatiques et des motifs -C(O)-(R14)-C(O)-
dérivant de diacides aromatiques, où R13 est choisi dans le groupe constitué par les
alkylènes en C0 à C20 et leurs mélanges et le pourcentage molaire des motifs dérivant de diacides aromatiques
est supérieur à 50 % et inférieur à 70 % du composant dicarboxylique ;
iii) 1 à 25 % en poids, par rapport au poids total de la composition polymère biodégradable, de fibres de cellulose ;
iv) 1 à 10 % en poids, par rapport au poids total de la composition polymère biodégradable, d'un agent de nucléation choisi parmi les polyesters comprenant des motifs répétitifs de succinate de 1,4-butylène, le talc, et leurs mélanges.
2. Composition biodégradable selon la revendication 1, dans laquelle le polyester d'acide
lactique est choisi dans le groupe constitué par le poly(acide L-lactique), le poly(acide
D-lactique) et un stéréocomplexe de poly(acide L-lactique) et de poly(acide D-lactique),
et leurs mélanges.
3. Composition biodégradable selon la revendication 1, dans laquelle le diacide aliphatique
de l'AAPE est l'acide succinique, l'acide adipique, l'acide subérique, l'acide azélaïque,
l'acide sébacique, l'acide undécanedioïque, l'acide dodécanedioïque, l'acide brassylique,
l'acide hexadécanedioïque, l'acide octadécanedioïque, ou un mélange de ceux-ci.
4. Composition biodégradable selon la revendication 1, dans laquelle le diacide aromatique
est choisi parmi les composés aromatiques dicarboxyliques du type acide phtalique
et leurs esters et les composés aromatiques hétérocycliques et leurs esters, ainsi
que leurs mélanges.
5. Composition biodégradable selon la revendication 4, dans laquelle le composé aromatique
hétérocyclique est l'acide 2,5-furanedicarboxylique.
6. Composition biodégradable selon la revendication 4, dans laquelle le composé aromatique
dicarboxylique du type acide phtalique est l'acide téréphtalique.
7. Composition biodégradable selon l'une quelconque des revendications 1 à 6, dans laquelle
l'AAPE est biodégradable conformément à la norme EN 13432.
8. Composition biodégradable selon l'une quelconque des revendications 1 à 7, dans laquelle
l'agent de nucléation comprend un mélange de polyesters comprenant des motifs répétitifs
de succinate de 1,4-butylène et de talc, ledit mélange comprenant 10 à 95 % en poids
desdits polyesters.
9. Composition biodégradable selon la revendication 8, dans laquelle les fibres présentent
un rapport longueur/diamètre < 40.
10. Composition biodégradable selon l'une quelconque des revendications 1 à 9, dans laquelle
le polyester comprenant des motifs répétitifs de succinate de 1,4-butylène est le
poly(succinate de 1,4-butylène).
11. Articles moulés par injection comprenant la composition biodégradable de l'une quelconque
des revendications 1 à 10.
12. Articles thermoformés comprenant la composition biodégradable de l'une quelconque
des revendications 1 à 10.
13. Procédé de recuit des articles moulés par injection de la revendication 11, ledit
procédé étant mis en oeuvre à une température comprise entre 70 et 150°C.
14. Procédé selon la revendication 13, mis en oeuvre dans un environnement non confiné
et à une température constante.
15. Procédé selon la revendication 14, mis en oeuvre à une température comprise entre
80 et 150°C et avec un temps de séjour compris entre 30 secondes et 60 minutes.
16. Procédé selon la revendication 13, mis en oeuvre dans un environnement confiné.
17. Procédé selon la revendication 16, mis en oeuvre dans des moules préchauffés à température
constante.
18. Procédé selon la revendication 17, mis en oeuvre à une température comprise entre
80 et 100°C et avec un temps de séjour compris entre 1 et 5 minutes.
19. Produits recuits pouvant être obtenus par le procédé de recuit de l'une quelconque
des revendications 13 à 18.